LOUISIANA CRUDE OIL REFINERY SURVEY REPORT Nineteenth Edition 2013 Survey By Ross LeBlanc Refining, Alternative Energy & Power Systems Program LOUISIANA DEPARTMENT OF NATURAL RESOURCES Stephen Chustz Secretary of Natural Resources Technology Assessment Division Tom Harris, Director Baton Rouge, Louisiana October 2014
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Refining, Alternative Energy & Power Systems Program
LOUISIANA DEPARTMENT OF NATURAL RESOURCES
Stephen Chustz Secretary of Natural Resources
Technology Assessment Division
Tom Harris,
Director
Baton Rouge, Louisiana October 2014
This edition of Louisiana Crude Oil Refinery Survey Report is funded 100% ($1621.70) with Petroleum Violation Escrow funds as part of the State Energy Conservation Program as approved by the U.S. Department of Energy and Louisiana Department of Natural Resources.
This public document was published at a total cost of $1621.70. 540 copies of this public document were published in this first printing at a total cost of $1621.70. The total cost of all printings of this document, including reprints, is $1621.70. This document was published by the Department of Natural Resources, 617 N. 3rd Street, Baton Rouge, LA, to promulgate the State Energy Conservation Plan developed under authority of P.L. 94-163. This material was printed in accordance with the standards for printing by State agencies established pursuant to R.S. 43:31. Printing of this material was purchased in accordance with the provisions of Title 43 of the Louisiana Revised Statutes.
Figures 1 Map and Highlights of Louisiana Refineries .......................................................................v 2 Operating Capacity of Louisiana and U.S. Refineries .......................................................18 3 Operating Rates (%), U.S., Texas Gulf Coast, Louisiana Gulf Coast Refineries ..............19 4 Louisiana Oil Production (Excluding OCS) and Refinery Operable Capacity ..................20 5 Historical Crude Oil Sources for Louisiana Refineries .....................................................21 6 Crude Oil Input Percentages by Source and Refinery .......................................................22
Tables 1 Louisiana Operating Refineries, Capacity and Throughput Changes from DNR Survey ...6 2 Louisiana Operating Refineries, Crude Capacity and Percent Product Slate December 31, 2013 DNR Survey ........................................................................................7 3 U.S. Department of Energy, Capacity of Louisiana Operable Petroleum Refineries as of January 1, 2013 ..........................................................................................9 4 U.S. Department of Energy, Production Capacity of Louisiana Operable Petroleum Refineries as of January 1, 2013 .......................................................................12 5 Oil and Gas Journal 2013 Worldwide Refining Survey Capacities of Louisiana Refineries as of January 1, 2014 .................................................13 6 Crude Oil Input Percentages by Source and Refinery .......................................................23 7 Louisiana Operating Refinery Mailing Address and Contact Information ........................24
ii
8 Louisiana Operating Refinery Locations ...........................................................................25 9 Louisiana Operating Refinery Name History (1980 – 2013) .............................................26 10 Louisiana Non-Operating Refinery Mailing Address and Contact Information ...............27 11 Louisiana Non-Operating Refinery Location and Status Information ...............................28 12 Louisiana Non-Operating Refinery Name History (1980 – 2013) ....................................29 13 Louisiana Operating Refineries not Surveyed by DNR………………………………….30
iii
Foreword Since 1989, the Technology Assessment Division of the Louisiana Department of Natural Resources (DNR) has periodically conducted surveys of Louisiana crude oil refineries. The results of the survey are compiled into a report focusing on developments that have occurred since the previous survey. These include an overview of the general direction of the industry and updated information on the current status of refinery ownership, mailing addresses, operating status, and key personnel. Tabulated statistical data, charts, and graphs relating to oil production, refinery crude oil sources, refinery margins, capacities, operating rates, and product slate are also presented. Information on both operating and non-operating refineries that are still intact is included. The time period covered by DNR’s current survey is January 1, 2013 – December 31, 2013, and is designed to complement the petroleum statistics published by the Energy Information Administration (EIA). DNR gratefully acknowledges permission to use the December 2, 2013 Oil and Gas Journal Worldwide Refining Survey results to provide another independent dataset for comparison. The operating refining capacities, operating rates, and product slate statistics presented in this report are prepared from data supplied by survey respondents. The information on the non-operating refineries is obtained from their owners, trustees, or management personnel and is current within a few weeks of publication. The data used to construct the charts and graphs on oil production, refinery margins, and crude oil sources is obtained from DNR’s database. The principal terms and phrases used in this report are the same as those used in EIA publications. The definitions of these terms can be found on page 4 of this report. The slight difference in meaning between operable and operating, when used to specify capacity or utilization rate, has caused some confusion. “Operable” refers to the maximum amount of crude oil capacity that a refinery can utilize to process crude oil in its atmospheric stills; “operating” refers to the amount of crude oil capacity actually utilized. See page 4 for detailed definitions. The Department of Natural Resources uses the information in this report to enhance the economic development efforts of the State by: • Developing information on State and Federal energy policies that affect the oil and gas
production and refining industries located in the State;
• Helping crude suppliers locate refining sources and refined petroleum product buyers locate sources of supply;
• Assisting new industries desiring to site facilities near refineries; and, • Providing information to parties evaluating refineries for possible purchase.
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v
Figure 1: Map and Highlights of Louisiana Refineries
1
Discussion
Overview Louisiana is a primary energy producing state with 417 million barrels in crude reserves (2012), ranking it 10th among the states (2nd if the Louisiana portion of the federal outer continental shelf (OCS) is included). Louisiana ranks 7th among the states in crude oil production (2nd if Louisiana OCS is included), with an estimated 54.8 million barrels produced in 2012. The Louisiana OCS territory is the most extensively developed and matured OCS territory in the United States. The Louisiana OCS territory has produced approximately 88.% of the 19.3 billion barrels of crude oil and condensate produced in the U.S. through the end of 2012. The discovery of these large quantities of crude oil led to the development of the refining and petrochemical industry in Louisiana. Louisiana’s refining capacity grew with oil production until about 1970 when Louisiana’s oil production peaked and began to decline. Refinery capacity continued to grow by processing more foreign oil and oil from other states as well. Approximately two thirds of refinery input is foreign crude. All refineries and refining companies are not created equal. There are small refineries and large ones. Some are quite complex, while others are relatively simple. A number are part of major, integrated oil companies, and some are independent. In addition to refining, integrated oil companies are engaged in all other aspects of the petroleum industry which range from the exploration of crude oil to the marketing of finished petroleum products. Independent refiners, on the other hand, purchase most of their crude oil on the open market rather than producing it. Refiners such as Placid Refining Co. and Calcasieu Refining Co. are examples of independent refiners. Major oil companies dominate the refining industry. The top 10 U.S. refiners, all of them major integrated oil companies, account for about 75% of the total domestic refinery charge capacity. Most of these have operations in Louisiana, either as wholly owned facilities such as the Baton Rouge ExxonMobil refinery, or as part owners or joint ventures such as Motiva Refineries in Norco and Convent. Many refineries are primarily fuels refineries, some are lube stock refineries, and others are petrochemical refineries. Shell’s refinery in St. Rose is a good example of a petrochemical refinery. All of its products are raw feed for a chemical plant. Table 2 (pg. 7 & 8) clearly shows the focus and product slate of the refiners in Louisiana. Besides the level of vertical integration of a refiner and the product mix of a refinery, industry analysts also look at capacity and complexity. A "complexity factor" is assigned to each process unit of a refinery based on its relative construction cost. The atmospheric crude distillation unit is assigned a value of one. For example, the cost of a fluidized catalytic cracker is six times greater than an atmospheric crude distillation unit of the same capacity, so its unit complexity factor is six.
2
Greater complexity does not necessarily go hand-in-hand with larger capacity. Some of the smaller facilities in Louisiana are the most complex. For example, the smaller lube and wax producing refineries of North Louisiana are quite complex when compared to some very large refineries in the state. EIA statistics show total U.S. petroleum consumption in 2012 dropped 1.8% to 18.49 million barrels per day (bpd). Finished motor gasoline dropped 0.8% to 8,682 thousand bpd, jet fuel dropped 1.8% to 1,398 thousand bpd, and overall distillate fuel decreased 0.6% to 3,827 thousand bpd in 2012. According to DNR’s survey, the Louisiana refinery operating rate was 87.4% for this survey period with little idle capacity. Figure 3 (pg. 19) compares Louisiana Gulf Coast, Texas Gulf Coast, and total U.S. refinery operating rates since 1989. The operating capacity for Louisiana refineries was 3,349,520 barrels per calendar day (bcd), a 2.89% increase from DNR’s previous survey. Table 1 (pg. 6) shows the details of operating capacity and throughput changes between DNR’s two most recent surveys. Figure 2 (pg. 18) shows the historical Louisiana and U.S. operating capacity since 1960. Regular gasoline accounted for 35% of Louisiana refinery production. A complete listing of Louisiana refinery products is shown in Table 2 (pg. 8). As reported in the Oil & Gas Journal’s 2013 Worldwide Refinery Report, worldwide refining capacity stood at 88 million bcd, a decrease by nearly 900,000 bcd from 88.9 million in 2012. The table to the right shows the ranking of the 10 largest refiners in the world according to crude capacity. There were no newcomers to the list, Saudi Aramco, moves up from 10th to the 5th spot. Other changes in position were Phillips66 moves from 8th to 10th place. Source: Oil & Gas Journal, Dec. 2, 2013
Operating Refinery Recent Changes Valero Refining Co. acquired Murthy Oil’s Meraux refinery in October 2011. Marathon’s expansion of its Garyville facility is complete and resulted in a capacity increase of 235,000 bcd. Marathon is also increasing its diesel exporting facilities and is currently expanding capacity by an additional 100,000 bcd. Valero Energy Co. completed a $3 billion expansion to increase diesel production at its refineries in Louisiana and Texas, which it will export overseas. The identity and location of each of the operating refineries is shown on the map in Figure 1 (pg. V). Mailing addresses and contacts are listed in Table 7 (pg. 24). Physical locations are listed in Table 8 (pg. 25), and name histories are listed in Table 9 (pg. 26).
World Rank Company Crude Capacity (bcd)
1 2 3 4 5 6 7 8 9 10
ExxonMobil Royal Dutch Shell Sinopec BP Saudi Aramco Valero Energy Petroleos de Venezuela SA China National Petroleum Chevron Phillips66
Non-Operating Refinery Recent Changes During this survey period there are no recent changes to non-operating refinery status. The identity and location of each of the non-operating refineries is shown on the map in Figure 1 (pg. v). Mailing addresses and contacts are listed in Table 10 (pg. 27). Physical locations, last known crude capacity, date last operated, and present status are described in Table 11 (pg. 28), and name histories are listed in Table 12 (pg. 29).
4
Definitions Barrels per calendar day - The amount of input that a distillation facility can process under usual operating conditions. The amount is expressed in terms of capacity during a 24-hour period and reduces the maximum processing capability of all units at the facility under continuous operation (see Barrels per Stream Day) to account for the following limitations that may delay, interrupt, or slow down production:
The capability of downstream facilities to absorb the output of crude oil
processing facilities of a given refinery. No reduction is made when a planned distribution of intermediate streams, through other than downstream facilities, is part of a refinery’s normal operation;
The types and grades of inputs to be processed;
The types and grades of products expected to be manufactured;
The environmental constraints associated with refinery operations;
The reduction of capacity for scheduled downtime due to such conditions as
routine inspection, maintenance, repairs, and turnaround; and
The reduction of capacity for unscheduled downtime due to such conditions as mechanical problems, repairs, and slowdowns.
Barrels per stream day - The maximum number of barrels of input that a distillation facility can process within a 24-hour period when running at full capacity under optimal crude oil and product slate conditions with no allowance for downtime. Charge capacity - The input (feed) capacity of the refinery processing facilities. Idle capacity - The component of operable capacity that is not in operation and not under active repair, but capable of being placed in operation within 30 days; and capacity not in operation, but under active repair that can be completed within 90 days. Operable capacity - The amount of capacity that, at the beginning of the period, is in operation; not in operation and not under active repair, but capable of being placed in operation within 30 days; or not in operation, but under active repair that can be completed within 90 days. Operable capacity is the sum of the operating and idle capacity and is measured in barrels per calendar day or barrels per stream day. Note: This survey uses the capacity at the end of the period. Operating capacity - The component of operable capacity that is in operation at the beginning of the period. Note: This survey uses the capacity at the end of the period. Operable utilization rate - Represents the utilization of the atmospheric crude oil distillation units. The rate is calculated by dividing the gross input to these units by the operable refining capacity of the units.
5
Operating utilization rate - Represents the utilization of the atmospheric crude oil distillation units. The rate is calculated by dividing the gross input to these units by the operating refining capacity of the units. Throughput - Is the actual barrels of crude oil processed by the atmospheric stills for the survey time period. Operating rate % - Throughput divided by 365 divided by operating capacity expressed as a percentage. Operable rate % - Throughput divided by 365 divided by operable capacity expressed as a percentage.
2. Capacity change from 12/31/2011 to 12/31/2013. Througput change from 12-month period ending 12/31/2011 to the 12-month period ending 12/31/2013.3.Formerly ConocoPhillips*Data from EIA Refinery Capacity Report 2013
19.31
Table 1
3.705,000 36,559,664
0.00
-4,201,146
32,000
1,481,683
181,033,448
Louisiana Operating Refineries 1
Capacity and Throughput Changes from DNR Survey 2
75,168,897
-1,637,500
0 82,175,176 -7,859,883
Throughput Change (%)
Refinery NamePrevious Survey
Operating Capacity (bcd)
1. Louisiana operating refineries with no atmospheric distillation capacity were not surveyed by DNR and not included in this table. These facilities are listed in table 13.
16,297,386
87.4 87.4
3,349,520 0 1,068,697,802
1. Louisiana operating refineries with no atmospheric distillation capacity were not surveyed by DNR and not included in this table. These facilities are listed in table 13.2. Formerly ConocoPhillips*Data from EIA Refinery Capacity Report 2013
Total La. Operating Capacity
0 38,041,347
70,967,751
74,315,293
0
0
0
0
0
0 179,395,948
80,136,000
78,044,400
169,126,500
94.2
89.3
100,681,701
23,617,407
0
21,549,923
0.0
80.9
110.3
89.6
0
86.6
83.3
74.4
100.1
2,086,203
13,205,941
49,447,000
138,812,420
0
26,177,791
3,092,177
68.8
55.7
68.9
0
0
0
0
0
65.1
88.9
87.1
92.2
68.9
89.6
65.1
0
0
87.1
88.9
68.8
55.7
0
92.2
89.3
0.0
100.1
74.4
83.3233,500
140,000
59,000
45,000
86.6
94.2
502,500
522,000
235,000
65,000
197,000
427,800
252,000
TNN
CLC
CTT
CLM
ATL
239,400
STN
TXC
MRT
EXX
CNB
GDH
HLL
INT
PLC
SHL
CTS
Valero Refining Co Meraux
Chalmette Refining LLC Chalmette
Calcasieu Refining Co Lake Charles
Marathon Petroleum Co LLC Garyville
Citgo Petroleum Corp Lake Charles
Phillips 662
Lake Charles*
ExxonMobil Refining & Supply Co Baton Rouge
Calumet Lubricants Co LP Cotton Valley
Phillips 662
Belle Chasse*
Throughput 1/1/2013 - 12/31/2013
(Barrels)
Calumet Lubricants Co LP Princeton*
DNR Fac. Code
Operating rate (%)
Idle capacity
(bcd)
Operable rate (%)
Operating capacity as of
12/31/2013 (bcd)
Table 2
Louisiana Operating Refineries 1
Calumet Shreveport LLC Shreveport
Data in this table may differ from data reported elsewhere for a different time period.
Data in this table may differ from data reported elsewhere for a different time period.
Table 2 (Continued)
Louisiana Operating Refineries 1
Crude Capacity and Percent Product Slate
December 31, 2013 DNR Survey
INT
PLC
MRP
0.0
42.2
5.00.032.0 0.0
0.015.5
0.0
GDH
HLL
0.028.0
0.0
0.0
1.7
3.9
35.8
42.4
0.0
0.0
4.07.0
7.8
0.0
4.1
0.0
1.7
3.5 3.3
0.00.0
0.0
6.631.5
22.1 15.91.3 0.4
3.0
2.0
1.6
4.6 7.0
2.2
7.6
10.0
0.0
0.0
5.10.2
0.0
0.0
3.7
0.0
0.0
0.69.0
1.3
5.7
0.1
0.0 0.0
0.9
2.5
0.0
0.0
10.80.0
4.8
14.7
41.4 12.2 0.0 6.30.04.5 23.2
3.623.4
79.0
2.0
0.0
0.0 9.2
0.0 1.2
1.7
2.0
6.5
1.9
0.00.0
11.8
0.0
9.3
14.5
0.0
5.0
1.8
4.0
1.0
0.0
18.2 22.8
0.0
0.3
11.8
19.6
0.0
11.2
4.1
0.0
19.1
38.2
26.2
33.1
13.0
25.9
0.0
0.0
0.0
0.0 0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
12.8
0.00.0
0.6
4.3
3.0
0.0
5.0
40.5
6.5
0.0
0.0
0.0
28.4
0.0
0.0
0.0
26.4
28.0
1.4
22.3
41.5
38.9
EXX
MRT
TXC
29.8
CNB
SHL
CLC
CTT
CLM*
ATL
TNN
CTS
STN
Product 1 Product 2ULSD LPGsJet/ Kero
Fuel oil
Other Diesel
Prem RFG
% of Total Product Slate
Product 3 All Other
Other Fuels Miscellaneous Other Products
NapthRes/ Coke
DNR Fac
Code Reg
Gasoline
30.8
1. Louisiana operating refineries with no atmospheric distillation capacity were not surveyed by DNR and not included in this table. These facilities are listed in table 13.
a. Third-party plantRecovery: 4. Pressure swing adsorption5. Cryogenic6. Membrane7. Other
NOTES
Capacity definitions: Capacity expressed in barrels per calendar day (b/cd) is the maximum number of barrels of input that can be processed during a 24-hr period, after making allowances for the following: (a) Types and grades of inputs to be processed. (b) Types and grades of products to be manufactured. (c) Environmental constraints associated with refinery operations. (d) Scheduled downtime such as mechanical problems, repairs, and slowdowns. Capacity expressed in barrels per stream day (b/sd) is the amount a unit can process when running at full capacity under optimal feedstock and product slate conditions. An asterisk (*) beside a refinery location indicates that the number has been converted from b/sd to b/cd using the conversion factor 0.95 for crude and vacuum distillation units and 0.9 for all downstream cracking and conversion units.
Hydrogen: Hydrogen volumes presented here represent either generation or upgrading to 90+% purity.
Catalytic reforming: 1. Semiregenerative reforming is characterized by shutdownof the reforming unit at specified intervals, or at the operator’s convenience, for in situ catalyst regeneration. 2. Cyclic regeneration reforming is characterized bycontinuous or continual regeneration of catalyst in situ in any one of several reactors that can be isolated from and returned to the reforming operation. This is accomplished without changing feed rate or octane. 3. Continuous regeneration reforming is characterized bythe continuous regeneration of part of the catalyst in a special regenerator, followed by continuous addition of this regenerated catalyst to the reactor. 4. Other includes nonregenerative reforming (catalyst isreplaced by fresh catalyst) and moving-bed catalyst systems.
Source: 1953 - 1975: U.S. Bureau of Mines, "Petroleum Refineries in the
Untied States and Puerto Rico" Annual
1976 - 1981: EIA, "Petroleum Refineries in the United States and
1995: Louisiana data from DNR survey, as of June 30, 1995
1997: Louisiana data from DNR survey, as of June 30, 1997
Figure 2Operating Capacity of Louisiana and U.S. Refineries
18
0
2
4
6
8
10
12
14
16
18
20
1961
1963
1965
1967
1969
1971
1973
1975
1977
1979
1981
1983
1985
1987
1989
1991
1993
1995
1997
1999
2001
2003
2005
2007
2009
2011
2013
Mill
ion
Bar
rels
per
Cal
end
ar D
ay
Louisiana
Total U.S.
DNR Technology Assessment Division
* Louisiana Gulf Coast includes the parishes of Vernon, Rapides, Avoyelles, Pointe Coupee, West Feliciana, East Feliciana,Saint Helena, Tangipahoa, Washington, and all parishes south thereof, Mississippi counties of Pearl River, Stone, George, Hancock,Harrison, and Jackson, and Alabama counties of Mobile and Baldwin.
Figure 4Louisiana Oil Production (Excluding OCS) and Refinery Operable Capacity
Source: Oil production data from DNR database; Refinery capacity data from DNR database and EIA, "Petroleum Supply Annual, Vol. 1" and EIA, Refinery Capacity Data Report
0
200
400
600
800
1,000
1,200
1,40019
00
1910
1920
1930
1940
1950
1960
1970
1980
1990
2000
2010
2020
2030
Mill
ion
Bar
rels
per
Yea
r
Refinery Capacity
Oil Production
Projected
DNR Technology Assessment Division
Source: DNR Database, from Refiner's Monthly Report, Form R-3
Figure 5Historical Crude Oil Sources for Louisiana Refineries
21
0
200
400
600
800
1000
120019
9119
9219
9319
9419
9519
9619
9719
9819
9920
0020
0120
0220
0320
0420
0520
0620
0720
0820
0920
1020
1120
1220
13
Mill
ion
Bar
rels
per
Yea
r
Foreign
Other States
OCS
Louisiana
DNR Technology Assessment Division
Source: DNR Database, from Refiner's Monthly Report, Form R-3
Figure 6Crude Oil Input Percentages by Source and Refinery
2013 DNR's R3 Report
DNR Technology Assessment Division
22
0 20 40 60 80 100
Alon
Calcasieu
Calumet - Prin.
Calumet - C.V.
Calumet - Shrev.
Chalmette
Citgo
ExxonMobil
Marathon
Motiva - Norc.
Motiva - Conv.
Pelican
Phillips 66 L.C.
Phillips 66 B.C.
Placid
Shell - St. R.
Valero - Meraux
Valero - Norc.
% From Louisiana
0 20 40 60 80 100
Alon
Calcasieu
Calumet - Prin.
Calumet - C.V.
Calumet - Shrev.
Chalmette
Citgo
ExxonMobil
Marathon
Motiva - Norc.
Motiva - Conv.
Pelican
Phillips 66 L.C.
Phillips 66 B.C.
Placid
Shell - St. R.
Valero - Meraux
Valero - Norc.
% From Federal OCS
0 20 40 60 80 100
Alon
Calcasieu
Calumet - Prin.
Calumet - C.V.
Calumet - Shrev.
Chalmette
Citgo
ExxonMobil
Marathon
Motiva - Norc.
Motiva - Conv.
Pelican
Phillips 66 L.C.
Phillips 66 B.C.
Placid
Shell - St. R.
Valero - Meraux
Valero - Norc.
% From Other States
0 20 40 60 80 100
Alon
Calcasieu
Calumet - Prin.
Calumet - C.V.
Calumet - Shrev.
Chalmette
Citgo
ExxonMobil
Marathon
Motiva - Norc.
Motiva - Conv.
Pelican
Phillips 66 L.C.
Phillips 66 B.C.
Placid
Shell - St. R.
Valero - Meraux
Valero - Norc.
% From Foreign
Refinery Louisiana Federal OCS Other States Foreign